Auto-adaptive braze dispensing systems and methods

ABSTRACT

Systems and methods for moving a substrate to a vision system using a robot; using the vision system to determine where a braze material is to be applied to the substrate; moving the substrate to a braze dispenser using the robot; applying a braze material to the substrate using the braze dispenser based on the determination from the vision system; and using the vison system to determine whether to apply additional braze to the substrate, including for the substrate of a component for gas turbine engine, such as configured for use in an aircraft.

FIELD

This disclosure relates to systems and methods for applying a brazematerial to a substrate, such as an aircraft engine component.

BACKGROUND

Brazing is technique used to join metals together by applying heat tomelt and flow a braze material onto a substrate. Typically, the brazematerial has a lower melting point than the adjoining metals, and it isbrought slightly above its melting temperature to melt and flow over thebase metal in a technique called wetting, which fills in an opening inthe substrate by capillary action to fill and/or close the opening.Appropriate capillary in-draw allows the braze material to bond with themetals and conjoin them as one.

Various types of engine and other components are used in workingenvironments that are detrimental to the components—e.g., environmentsthat reduce wall thickness and/or create cracks and holes in a substratethrough corrosion, erosion, exposure to high operating temperatures,oxidation, thermal fatigue, etc. Accordingly, brazing can be used torework a component into a desired configuration or geometry.Advantageously, the braze material can affect the material propertiesand/or shape of the substrate, thereby reducing production costs,allowing re-works, and extending the working life of various components.

SUMMARY

In various embodiments, a brazing system includes a vision system havinga camera, a sensor, and a vision processor module; a braze dispenserhaving a braze head, a braze nozzle, and a braze processor module; arobot having an articulating arm; a control interface having an inputdevice and an output device; and a processing module having a controllerand memory configured to communicate with and control the vision system,the braze dispenser, the robot, and the control interface; wherein thevision system is configured to determine where the braze dispenser is toapply a braze material to a substrate and whether the braze dispenser isapply additional braze material to the substrate after an initialapplication.

In various embodiments: the processing module is configured to receivecommands from the input device to communicate with and control thevision system, the braze dispenser, and the robot; and/or the processingmodule is configured to communicate with and control the articulatingarm of the robot; and/or the processing module is configured tocommunicate with and control the articulating arm of the robot to placethe substrate proximate the vision system; and/or the processing moduleis configured to communicate with and control the articulating arm ofthe robot to place the substrate proximate the braze dispenser; and/orthe processing module is configured to communicate with and control thebraze dispenser to apply the braze material to the substrate based ondeterminations from the vision system; and/or the substrate is acomponent of a gas turbine engine; and/or the gas turbine engine isconfigured for use in an aircraft.

In various embodiments, an automated method of applying a braze materialto a substrate includes moving a substrate to a vision system using arobot; using the vision system to determine where a braze material is tobe applied to the substrate; moving the substrate to a braze dispenserusing the robot; applying a braze material to the substrate using thebraze dispenser based on the determination from the vision system; andusing the vison system to determine whether to apply additional brazematerial to the substrate.

In various embodiments: the braze dispenser applies the braze materialto the substrate at approximately 0.011-0.11 pounds (5-50 grams) perminute; and/or the braze dispenser applies the braze material to thesubstrate at approximately 0.008-0.016 inches (0.2-0.4 millimeters) perpass; and/or a thickness of the applied braze material is approximately0.01-0.06 inches (0.254-1.524 millimeters); and/or the braze dispenserapplies the braze material to the substrate at a distance ofapproximately 0.049-0.059 inches (1.25-1.5 millimeters) away from thesubstrate; and/or the substrate is a component of a gas turbine engine;and/or the gas turbine engine is configured for use in an aircraft.

In various embodiments, an automated method of applying a braze materialto a component of a gas turbine engine of an aircraft includes movingthe component to a vision system using a robot; using the vision systemto determine where a braze material is to be applied to the component;moving the component to a braze dispenser using the robot; applying abraze material to the component using the braze dispenser based on thedetermination from the vision system; and using the vison system todetermine whether to apply additional braze material to the component.

In various embodiments: the braze dispenser applies the braze materialto the component at approximately 0.011-0.11 pounds (5-50 grams) perminute; and/or the braze dispenser applies the braze material to thecomponent at approximately 0.008-0.016 inches (0.2-0.4 millimeters) perpass; and/or a thickness of the applied braze material is approximately0.01-0.06 inches (0.254-1.524 millimeters); and/or the braze dispenserapplies the braze material to the component at a distance ofapproximately 0.049-0.059 inches (1.25-1.5 millimeters) away from thecomponent.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate various embodiments employing theprinciples described herein and are a part of this specification. Theillustrated embodiments are meant for description only, and they do notlimit the scope of the claims, and in which:

FIG. 1 is a simplified schematic representation of a brazing systemaccording to the inventive arrangements, in various embodiments;

FIG. 2 is a partially perspective view of a brazing system, in variousembodiments;

FIG. 3 is a flow chart of a brazing method, in various embodiments;

FIG. 4 is a simplified cross-sectional side view of an exemplary gasturbine engine, in various embodiments; and

FIG. 5 depicts a representative substrate, in various embodiments.

DETAILED DESCRIPTION

This detailed description of exemplary embodiments references theaccompanying drawings, which show exemplary embodiments by way ofillustration. While these exemplary embodiments are described insufficient detail to enable those skilled in the art to practice thisdisclosure, it should be understood that other embodiments may berealized and that logical changes and adaptations in construction anddesign may be made in accordance with this disclosure and the teachingsdescribed herein without departing from the scope and spirit of thisdisclosure. Thus, this detailed description is presented for purposes ofillustration only and not of limitation.

In accordance with various aspects of this disclosure, systems andmethods are described for applying a braze material to a substrate. Forexample, a braze material can be applied to a combustion liner of gasturbine engine, such as one configured for use in an aerospaceapplication.

Referring now to FIGS. 1-2 and/or in various embodiments, a brazingsystem 10 comprises a vision system 20, a braze dispenser 30, a robot40, and/or a control interface 50. In various embodiments, the brazingsystem also comprises a processing module 60—e.g., a microprocessor anda tangible, non-transitory memory—in electrical and/or RF communicationwith the vision system 20, the braze dispenser 30, the robot 40, and/orthe control interface 50.

Referring to FIG. 1, and/or in various embodiments, the vision system 20includes a camera 22, a sensor 24, and a vision processor module 26comprising a processor and a tangible, non-transitory memory, eachconfigured to operate together to recognize a region of a substrate towhich a braze application is to be made—i.e., to which a braze materialis to be applied. In various embodiments, the vision system 20 utilizesthe camera 22 to identify a crack or hole in the substrate to which thebraze material is to be applied, such as by identifying an outline ofthe crack or hole against an expected configuration, such as accessedand/or stored by the vision processor module 26 and/or the processingmodule 60. In various embodiments, the vision system 20 utilizes thesensor 24 and vision processor module 26 to analyze outputs from thecamera 22 to detect or determine an outline of the crack or hole intowhich the braze material is to be flowed. For example, in variousembodiments, the camera 22 obtains an image of the substrate, and thesensor 24 and/or vision processor module 26 determines from that imagethe outline of the crack or hole by detecting edges of the crack or holeand areas adjoining and/or around the crack or hole to determine theregion of the substrate to which the braze material is to be applied.For example, in various embodiments, the sensor 24 senses the surface ofthe substrate, and the vision processor module 26 analyzes output(s)from the camera 22 and/or sensor 24 to determine the edges of the crackor hole. In various embodiments, these parameters are stored as aplurality of coordinates as related to the substrate.

If the vision system 20 is unable to locate all or any cracks or holeson the substrate in need of a braze application, then the robot 40 candefault to cooling hole data provided at the control interface and/orprogrammed into the processing module 60, in various embodiments.

In various embodiments, the camera 22 and/or sensor 24 and/or visionprocessor module 26 is/are also used to confirm an orientation and/orpositon of the substrate prior to applying the braze material.

In various embodiments, the braze dispenser 30 includes a braze head 32,a braze nozzle 34, and a braze processor module 36 comprising aprocessor and a tangible, non-transitory memory, each configured tooperate together to apply the braze material to the region of thesubstrate determined and/or identified by the vision system 20. Invarious embodiments, the braze material applied by the braze head 32 andbraze nozzle 34 is a function of the substrate material. For example, invarious embodiments, the braze material is an elemental material and/ormetal—such as, for example, aluminum, boron, chromium, cobalt, copper,gold, hafnium, iron, magnesium, molybdenum, nickel, palladium, rhenium,silicon, silver, tantalum, tin, titanium, tungsten, zinc, zirconium,etc. In various embodiments, the braze material is an amalgamation,alloy, and/or superalloy of various materials and/or metals—such as, forexample, various combinations of aluminum, boron, chromium, cobalt,copper, gold, hafnium, iron, magnesium, molybdenum, nickel, palladium,rhenium, silicon, silver, tantalum, tin, titanium, tungsten, zinc,zirconium, and/or other additives or adjuncts. In various embodiments,adhesive materials are added to the braze material to obtain desiredproperties thereof. In various embodiments, binder materials are addedto the braze material to obtain desired properties thereof. In variousembodiments, carrier materials are added to the braze material to obtaindesired properties thereof. In various embodiments, filler materials areadded to the braze material to obtain desired properties thereof.

In various embodiments, the braze dispenser 30 works with brazematerials that are in coating, foil, liquid, paste, putty, slurry, solid(e.g., powdered), and/or tape forms.

In various embodiments, the braze material is brought to and/or held ata temperature above the melting temperature of the braze material, butbelow the melting temperature of the metals or materials being joined(i.e., the substrate), such as above or below 842 degrees Fahrenheit(450 degree Celsius), in various applications. For example, in variousembodiments, the braze nozzle 34 is positioned proximate and/or heldabove a surface of the substrate to be joined and the temperature of thebraze material is raised to and/or held at or above the meltingtemperature of the braze material (e.g., the braze temperature), butbelow the melting temperature of the substrate. The braze material thusbecomes molten, wets adjacent surfaces of the substrate when appliedthereto, and, through capillary action, is drawn into and fills in gapsin the substrate, in various embodiments. In various embodiments, thebraze material cools and/or is cooled, by which the braze materialsolidifies and forms a strong metallurgical bond with the substrate at abrazement joint. In various embodiments, bonding occurs at molecularlevels of the braze material and/or substrate. In various embodiments,the brazement joint provides a desired degree of serviceability undervarious temperatures, stresses, vibration loads, etc. In variousembodiments, the braze joint is superior to the original substrate invarious aspects.

In various embodiments, the vision system 20 is used to orient and/orconfirm the orientation of the substrate prior to the braze application.

In various embodiments, the vision system 20 is used to inspect thebraze application before, during, and/or after the braze application iscompleted.

In various embodiments, the braze process is repeated one or more times.

In various embodiments, the vision system 20 is used to determine if thebraze process should be and/or is repeated one or more times.

In various embodiments, the braze dispenser 30 is controlled to apply anamount of braze material to the crack or hole corresponding to an amountand/or location as determined by the vision system 20 regarding thesubstrate.

In various embodiments, the vision system 20 is used to determine if thesubstrate should be and/or is subjected to a follow-up braze removaltechnique—e.g., grinding—following the braze application to remove anyexcess braze that may have occurred during the brazing application.

In various embodiments, the robot 40 includes an articulating arm 42configured to gather, hold, move, pick, position, and/or release thesubstrate, including proximate and/or under the vision system 20 and/orthe braze dispenser 30.

In various embodiments, the articulating arm 42 is configured to bemovable according to a plurality of coordinate axes within and/ordefined by the brazing system 10.

In various embodiments, the robot 40 is configured to be movable so thatan operator operating the control interface 50 can manipulate and/orview the substrate within the brazing system 10.

In various embodiments, the articulating arm 42 is configured to bemovable so that an operator operating the control interface 50 canmanipulate and/or view the substrate within the brazing system 10.

In various embodiments, the articulating arm 42 is configured to bemovable so that the vision system 20 inspects the substrate frommultiple angles, axes, orientations, and/or views. For instance, theportion(s) of the substrate in need of brazing may be present in anynumber of locations and/or surfaces of the component. In addition, theportion(s) of the substrate in need of brazing may be present in anynumber of sizes and shapes on the component, in various embodiments.

In various embodiments, the articulating arm is the only and/or primarypart of the brazing system 10 that moves, the vision system 20 and brazedispenser 30 otherwise being stationary, in various embodiments.

In various embodiments, the control interface 50 includes an inputdevice 52 and an output device 54, configured to interact with and/oroperate the brazing system 10. For example, in various embodiments, theinput device 52 comprises, for example, a keyboard, mouse, touch screen,etc. for inputting commands, directions, instructions, and/or the liketo the brazing system 10. In various embodiments, the input device 52 isconfigured to allow an operator to control the vision system 20, thebraze dispenser 30, and/or the robot 40. In various embodiments, theoutput device 54 comprises, for example, a display. In variousembodiments, the output device 54 is configured to allow the operator toview images from the vision system 20.

In various embodiments, the control interface 50 of the brazing system10 is configured to allow an operator to control and/or positon thevision system 20, the braze dispenser 30, and/or the robot 40.

In various embodiments, the control interface 50 is configured to allowan operator to control movement, orientation, and/or position of thesubstrate that the robot 40 brings to the brazing system 10, includingproximate to the vision system 20 and/or braze dispenser 30.

In various embodiments, the control interface 50 is configured to allowthe operator to control the braze head 32 and braze nozzle 34 throughthe braze processor module 36. For example, in various embodiments, anoperator can control the type of braze material flowing through thebraze dispenser 30. In various embodiments, an operator can control theflow rate of the braze material flowing through the braze dispenser 30,such as monitoring and/or controlling a flow rate of the braze materialthrough the braze nozzle 34.

In various embodiments, a flow rate of the braze material through thebraze nozzle 34 is approximately 0.011-0.11 pounds (5-50 grams) perminute, such as approximately 0.055 pounds (25 grams) per minute.

In various embodiments, an application rate of the braze materialthrough the braze nozzle 34 is approximately 0.008-0.016 inches (0.2-0.4millimeters) per pass, such as approximately 0.012 inches (0.3millimeters) per pass.

In various embodiments, a thickness of the applied braze material is atleast 0.01 inches (0.254 millimeters). For example, in variousembodiments, a thickness of the applied braze material is approximately0.01-0.06 inches (0.254-1.524 millimeters), such as approximately 0.035inches (0.9 mm).

In various embodiments, the braze nozzle 34 does not contact thesubstrate, but instead stays a suitable distance from the substrate whenthe braze material is being dispensed. For example, in variousembodiments, the braze dispenser applies the braze material at adistance of approximately 0.049-0.059 inches (1.25-1.5 millimeters) awayfrom the substrate, such as approximately 0.054 inches (1.372 mm) awayfrom the substrate.

In various embodiments, the processing module 60 of the brazing system10 communicates with and controls the vision system 20, the brazedispenser 30, the robot 40, and/or the control interface 50, asdescribed herein. More specifically, the processing module 60, invarious embodiments, includes one or more controllers 62 (e.g.,processors) and one or more tangible, non-transitory memories 64 capableof implementing digital or programmatic logic. In various embodiments,for example, the one or more controllers 62 are one or more of anapplication specific integrated circuit (ASIC), digital signal processor(DSP), field programmable gate array (FPGA), general purpose processor,and/or other programmable logic device, discrete gate, transistor logic,or discrete hardware components, or any various combinations thereof orthe like, and the one or more memories 64 store instructions that areimplemented by the one or more controllers 62 for performing variousfunctions, such as controlling the brazing system 10 as describedherein. As such, the brazing system 10 is, in various embodiments, anauto-adaptive brazing dispensing system operative in response to variouscontrol and/or electronic signals. In various embodiments, the brazingsystem 10 operates in an automated and/or semi-automated fashion.

In various embodiments, the brazing system 10 is configured to onlyoperate if a locking mechanism is engaged, such as a closing and/orlocking a door of the brazing system 10 before and/or during a brazingapplication.

In various embodiments, the brazing system 10 is configured to onlyoperate if the substrate is loaded into the brazing system 10 in apredetermined way. For example, in various embodiments, the robot 40 isconfigured to only operate if the substrate is loaded into the brazingsystem 10 in a predetermined way. If the substrate is not loaded intothe brazing system 10 in a predetermined way, then the brazing system10, braze dispenser 30, and/or robot 40 are configured to not operate,in various embodiments.

In various embodiments, the brazing system 10 is programmed to know thenumber of substrates to which a brazing application is to be made.

In various embodiments, the vision system is programmed to recognizedifferent types of substrates.

In various embodiments, the brazing system 10 is programmed to makedifferent brazing applications to different substrates and/or differenttypes of substrates.

In various embodiments, the robot 40 is configured to not make anincorrect braze application to a particular substrate.

In various embodiments, the brazing system 10 is configured to operateonly if an expected substrate is recognized by the vision system 20and/or configured to not operate without a substrate being within thebrazing system 10.

In various embodiments, the brazing system 10 is configured to only makea braze application at a specified location on the substrate and/or tonot make a braze application at an unspecified location on thesubstrate.

In various embodiments, the braze dispenser 30 is programmed to apply apredetermined braze material at a predetermined location, to apply apredetermined mass of a braze material at a predetermined location, tooperate with a particular density of braze material, to operate with apredetermined end effector to apply the braze, to operate with apredetermined braze material deposition rate, to perform a self-testand/or periodic self-tests on a sample substrate, etc.

Referring now to FIG. 3, a method 300 begins at a step 302. Thereafter,a robot picks up a substrate at a step 304—such as picking up a fixtureholding a substrate preloaded into the fixture, in various embodiments.Thereafter, the robot moves the substrate to a vision system at a step306—such as moving the substrate to within operable proximity of thevision system. Thereafter, the vision system determines where to apply abraze material to the substrate at a step 308—such as by identifyingcracks or holes of the substrate by comparison against expectedparameters. Thereafter, the robot moves the substrate to a brazedispenser at a step 310—such as moving the substrate to within operableproximity of the braze dispenser. Thereafter, the braze dispenserapplies a braze material to the substrate at a step 312—such as applyingthe braze material to the substrate in the amounts and/or at thelocations identified by the vision system. Thereafter, the robot movesthe substrate to the vision system at a step 314—such as moving thesubstrate back to within operable proximity of the vision system.Thereafter, the vision system identifies if additional and/or more brazematerial should be applied to the substrate at a step 316. If additionaland/or more braze material should be applied to the substrate, themethod 300 returns control to step 308 at step 316. Otherwise, the robotreleases the substrate at a step 318 following step 316—such asdischarging the substrate from the robot. Thereafter, the method 300ends at a step 320.

Referring now to FIG. 4, a representative gas turbine engine 420 is atwo-spool turbofan that incorporates a fan section 422, a compressorsection 424, a combustor section 426, and a turbine section 428. Invarious embodiments, the gas turbine engine 420 includes other systemsand features too.

In various embodiments, the fan section 422 is positioned towards afront or inlet of the gas turbine engine 420, and it includes a fan 442that induces air from a surrounding environment into the gas turbineengine 420 and accelerates a portion of the air towards the compressorsection 424.

In various embodiments, the fan section 422 drives the air along abypass flowpath B while the compressor section 424 drives the air alonga core flowpath C for acceleration, compression, and communication intothe combustor section 426, then expansion through the turbine section428.

In various embodiments, the compressor section 424 raises the pressureof the air received from the fan section 422 to a relatively high level.The compressed air from the compressor section 424 then enters thecombustor section 426, where one or more fuel nozzles inject fuel intothe compressed air. The fuel-air mixture is ignited in the combustorsection 426 to generate combustion gases. The high-energy combustiongases from the combustor section 426 then flow into and through theturbine section 428, thereby causing rotationally mounted turbine bladesto rotate and generate energy. The air exiting the turbine section 428is exhausted from the gas turbine engine 420 via an exhaust section.

In various embodiments, the gas turbine engine 420 includes one or moreof a low pressure compressor (LPC) 444, a high pressure compressor (HPC)452, a high pressure turbine (HPT) 454, and/or a low pressure turbine(LPT) 446.

In various embodiments, the gas turbine engine 420 is or includes othertypes of engines, such as turbojets, turboshafts, three-spool (plus fan)turbofans, and/or direct drive turbofans. In various embodiments, anintermediate spool includes an intermediate pressure compressor (notshown) between the LPC 444 and the HPC 452 and/or an intermediatepressure turbine (not shown) between the HPT 454 and the LPT 446.

In various embodiments, the gas turbine engine 420 includes a low spool430 and a high spool 432 mounted for rotation about an engine centrallongitudinal axis A-A′ relative to an engine static structure or enginecase 436 via multiple bearing structures. In various embodiments, thelow spool 430 includes an inner shaft 440 that interconnects the fan 442of the fan section 422, the LPC 444 of the compressor section 424, andthe LPT 446 of the turbine section 428. In various embodiments, theinner shaft 440 communicates with the fan 442 directly or through ageared architecture 448 to drive the low spool 430 at a higher speedthan the fan 442. In various embodiments, a reduction transmission is anepicyclic transmission, such as a planetary or star gear system.

In various embodiments, the high spool 432 includes an outer shaft 450that interconnects the HPC 452 of the compressor section 424 and the HPT454 of the turbine section 428. In various embodiments, a combustionchamber 456 is arranged between the HPC 452 and the HPT 454. In variousembodiments, the inner shaft 440 and the outer shaft 450 are concentricand rotate about the engine central longitudinal axis A-A′ that iscollinear with their longitudinal axes. Core airflow flowing along coreflowpath C is compressed by the LPC 444, further compressed by the HPC452, mixed with fuel, burned in the combustion chamber 456, and thenexpanded over the HPT 454 and the LPT 446. In various embodiments, theHPT 454 and the LPT 446 rotationally communicate with the high spool 432and the low spool 430, respectively, in response to the expansion.

In various embodiments, the gas turbine engine 420 is a high-bypassgeared aircraft engine. In various embodiments, the gas turbine engine420 bypass ratio is greater than approximately 6:1. In variousembodiments, the geared architecture 448 includes an epicyclic geartrain, such as a planetary gear system or other gear system. In variousembodiments, the example epicyclic gear train has a gear reduction ratioof greater than approximately 2.3:1, and, in other embodiments, it isgreater than approximately 2.5:1. In various embodiments, the gearedturbofan enables operation of the low spool 430 at higher speeds thatcan increase the operational efficiency of the LPC 444 and the LPT 446and render increased pressure in a fewer number of stages.

A pressure ratio associated with the LPT 446 is pressure measured priorto the inlet of the LPT 446 as related to the pressure at the outlet ofthe LPT 446 prior to an exhaust nozzle of the gas turbine engine 420. Invarious embodiments, the bypass ratio of the gas turbine engine 420 isgreater than approximately 10:1, the fan 442 diameter is significantlylarger than that of the LPC 444, and the LPT 446 has a pressure ratiothat is greater than approximately 5:1.

In various embodiments, a significant amount of thrust is provided bythe bypass flowpath B due to the high bypass ratio. In variousembodiments, the fan section 422 is suited for a particular flightcondition—e.g., cruising at approximately 0.8 Mach and/or approximately35,000 feet (10,668 meters). This flight condition, with the gas turbineengine 420 at a preferred fuel consumption, is known as thrust specificfuel consumption (TSFC), which is an industry-standard parameter of fuelconsumption per unit of thrust.

Fan pressure ratio is a pressure ratio across a blade of the fan 442 inthe fan section 422 without using a fan exit guide vane system. Invarious embodiments, a low fan pressure ratio of the gas turbine engine420 is less than 1.45. A low corrected fan tip speed is the actual fantip speed divided by an industry-standard temperature correction of(T/518.7)^(0.5), in which T is an ambient temperature measurement indegrees Rankine. In various embodiments, the low corrected fan tip speedof the gas turbine engine 420 is less than approximately 1,150 feet (351meters) per second.

In various embodiments, the combustion chamber 456 contains thecombustion products that flow axially toward the turbine section 428. Invarious embodiments, an outer wall and/or an inner wall are generallycylindrical and extend circumferentially about the engine centrallongitudinal axis A-A′. In various embodiments, one or more of the outerwall and/or the inner wall are formed utilizing shells and panels. Invarious embodiments, the shells and/or panels are circumferentiallycontinuous (e.g., ring shaped) and divided axially, dividedcircumferentially from each, and/or both (e.g., substantiallyrectilinear in shape).

In various embodiments, the inventive arrangements can be applied to anyof the afore-mentioned engine components, including, for example,airfoils, blades, buckets, combustors, nozzles, shrouds, vanes, walls,etc.

Referring now to FIG. 5, a representative substrate 500 is depicted,which can be a component of a gas turbine engine, such as depicted inFIG. 4, to which a braze application is to be made. For example, thesubstrate 500 could be on airfoil, related to platform holes of a vanestructure, etc. In various embodiments, the substrate 500 is carried ona holding tray 502 or the like for transportation by the robot 40 ofFIGS. 1-2 to and/or within the vision system 20 of FIGS. 1-2. In variousembodiments, the holding tray 502 (or substrate 500) includes anidentifier 504 such as a bar code or the like that the vision system 20of FIGS. 1-2 is programmed to recognize.

Technical benefits and effects of this disclosure include providingbraze dispensing systems and methods for applying a braze material to asubstrate, such as from a gas turbine engine, an aircraft gas turbineengine, etc., to improve the usability and/or re-usability thereof,including if a substrate has a crack or hole, allowing a flowed brazematerial to meet or exceed quality and/or standards of the componentfollowing the braze application, thereby reducing production costs,allowing re-works, extending the working life of various components,etc.

Advantages, benefits, and/or solutions to problems have been describedherein with regard to specific embodiments. Furthermore, connectinglines shown in the various figures contained herein are intended torepresent exemplary functional relationships and/or physical couplingsbetween the various elements. It should be noted that many additionaland/or functional relationships or physical connections may be presentin a practical system. However, the advantages, benefits, and/orsolutions to problems, and any elements that may cause any advantage,benefit, and/or solution to occur or become more pronounced are not tobe construed as critical, essential, and/or required elements orfeatures of this disclosure.

The scope of this disclosure is accordingly to be limited by nothingother than the appended claims, in which reference to an element in thesingular is not intended to mean “one and only one” unless explicitly sostated, but rather “one or more.” It is to be understood that unlessspecifically stated otherwise, references to “a,” “an,” and/or “the” mayinclude one or more than one, and that reference to an item in thesingular may also include the item in the plural, and vice-versa. Allranges and ratio limits disclosed herein may be combined.

Moreover, where a phrase similar to “at least one of A, B, and C” isused in the claims, it is intended that the phrase be interpreted tomean that A alone may be present in an embodiment, B alone may bepresent in an embodiment, C alone may be present in an embodiment, orthat any combination of the elements A, B, and C may be present in asingle embodiment; for example, A and B, A and C, B and C, or A and Band C. Different cross-hatching is used throughout the figures to denotedifferent parts, but not necessarily to denote the same or differentmaterials. Like depictions and/or numerals also generally represent likeelements.

The steps recited in any of the method or process descriptions may beexecuted in any order and are not necessarily limited to the orderpresented. Furthermore, any reference to singular elements, embodiments,and/or steps includes plurals thereof, and any reference to more thanone element, embodiment, and/or step may include a singular one thereof.Elements and steps in the figures are illustrated for simplicity andclarity and have not necessarily been rendered according to anyparticular sequence. For example, steps that may be performedconcurrently or in different order are only illustrated in the figuresto help to improve understanding of embodiments of the present,representative disclosure.

Any reference to attached, fixed, connected, or the like may includepermanent, removable, temporary, partial, full and/or any other possibleattachment option. Additionally, any reference to without contact (orsimilar phrases) may also include reduced contact or minimal contact.Surface shading lines may be used throughout the figures to denotedifferent parts or areas, but not necessarily to denote the same ordifferent materials. In some cases, reference coordinates may or may notbe specific to each figure.

Systems, methods, and apparatus are provided herein. In the detaileddescription herein, references to “one embodiment,” “an embodiment,”“various embodiments,” etc., indicate that the embodiment described mayinclude a particular characteristic, feature, and/or structure, butevery embodiment may not necessarily include this particularcharacteristic, feature, and/or structure. Moreover, such phrases arenot necessarily referring to the same embodiment. Further, when aparticular characteristic, feature, and/or structure is described inconnection with an embodiment, it is submitted that it is within theknowledge of one skilled in the art to affect such characteristic,feature, and/or structure in connection with other embodiments, whetheror not explicitly described. After reading the description, it will beapparent to one skilled in the relevant art(s) how to implement thisdisclosure in alternative embodiments.

Furthermore, no component, element, or method step in the presentdisclosure is intended to be dedicated to the public regardless ofwhether the component, element, or method step is explicitly recited inthe claims. No claim element is intended to invoke 35 U.S.C. § 112(f)unless the element is expressly recited using the phrase “means for.” Asused herein, the terms “comprises,” “comprising,” or any other variationthereof, are intended to cover a non-exclusive inclusion, such that anapparatus, article, method, and/or process, method that comprises a listof elements does not include only those elements, but it may alsoinclude other elements not expressly listed or inherent to suchapparatus, article, method, and/or process.

What is claimed is:
 1. An automated method of applying a braze materialto a substrate, comprising: moving the substrate to a vision systemusing a robot controlled by a controller, the controller configured tocommunicate with and control the vision system, a braze dispenser, therobot, and a control interface; subsequently identifying, by the visionsystem, an identifier for the substrate; subsequently identifying, bythe vision system, an expected configuration based on the identifier;subsequently identifying, by the vision system, a crack or a hole in thesubstrate based on the expected configuration of the substrate;subsequently determining, by the vision system, a first location wherethe braze material is to be applied to the substrate based onidentifying the crack or the hole; moving the substrate to the brazedispenser using the robot; applying the braze material to the substrateusing the braze dispenser based on the first location from the visionsystem; and determining, by the vision system, whether to applyadditional braze material to the substrate at a second location.
 2. Theautomated method of claim 1, wherein the braze dispenser applies thebraze material to the substrate at approximately 0.011-0.11 pounds (5-50grams) per minute.
 3. The automated method of claim 1, wherein the brazedispenser applies the braze material to the substrate at approximately0.008-0.016 inches (0.2-0.4 millimeters) per pass.
 4. The automatedmethod of claim 1, wherein a thickness of the applied braze material isapproximately 0.01-0.06 inches (0.254-1.524 millimeters).
 5. Theautomated method of claim 1, wherein the braze dispenser applies thebraze material to the substrate at a distance of approximately0.049-0.059 inches (1.25-1.5 millimeters) away from the substrate. 6.The automated method of claim 1, wherein the substrate is a component ofa gas turbine engine.
 7. The automated method of claim 6, wherein thegas turbine engine is configured for use in an aircraft.
 8. An automatedmethod of applying a braze material to a component of a gas turbineengine of an aircraft, comprising: moving the component to a visionsystem using a robot controlled by a controller, the controllerconfigured to communicate with and control the vision system, a brazedispenser, the robot, and a control interface; subsequently identifying,by the vision system, an identifier for the component subsequentlyidentifying, by the vision system, an expected configuration based onthe identifier; subsequently identifying, by the vision system, a crackor a hole in the component based on the expected configuration of thecomponent; subsequently determining, by the vision system, a firstlocation where the braze material is to be applied to the componentbased on identifying the crack or the hole; moving the component to thebraze dispenser using the robot; applying the braze material to thecomponent using the braze dispenser based on the first location from thevision system; and determining, by the vision system, whether to applyadditional braze material to the component at a second location.
 9. Theautomated method of claim 8, wherein the braze dispenser applies thebraze material to the component at approximately 0.011-0.11 pounds (5-50grams) per minute.
 10. The automated method of claim 8, wherein thebraze dispenser applies the braze material to the component atapproximately 0.008-0.016 inches (0.2-0.4 millimeters) per pass.
 11. Theautomated method of claim 8, wherein a thickness of the applied brazematerial is approximately 0.01-0.06 inches (0.254-1.524 millimeters).12. The automated method of claim 8, wherein the braze dispenser appliesthe braze material to the component at a distance of approximately0.049-0.059 inches (1.25-1.5 millimeters) away from the component.